Foldable box or tray

ABSTRACT

A tray comprising a cover comprising a planar rectangular panel having a flap on each edge. The cover can also include a gusset coupling at least one flap to an adjacent flap. There can also be at least one tab coupled to at least one flap and an insert comprising a planar rectangular base which is substantially the same size as the planar rectangular panel. There can also be a plurality of flaps coupled to the base with at least one flap coupled to each edge of the base. In addition, there can be at least one additional cover, comprising a planar rectangle, wherein in use, the first cover is wrapped around the insert to form a full cover over the insert while the additional cover is wrapped around the cover to cover over an opening tray section, to form a substantially closed box.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation in part application, and Applicant claims priority under 35 U.S.C. § 120 from U.S. patent application Ser. No. 10/639,341 filed on Aug. 12, 2003.

BACKGROUND OF THE INVENTION

The invention relates to a foldable boxlike device or tray, which can be made from multiple parts including an insert, a first cover, and a second cover. The insert, the first cover, and the second cover, are all foldable such that they can be folded up and coupled together to form a new and improved tray or box.

SUMMARY OF THE INVENTION

The invention can relate to a tray comprising a cover comprising a planar rectangular panel having a flap on each edge. The cover can also include a gusset coupling at least one flap to an adjacent flap. There can also be at least one tab coupled to at least one flap and an insert comprising a planar rectangular base which is substantially the same size as the planar rectangular panel. There can also be a plurality of flaps coupled to the base with at least one flap coupled to each edge of the base. In addition, there can be at least one additional cover, comprising a planar rectangle, wherein in use, the first cover is wrapped around the insert to form a full cover over the insert while the additional cover is wrapped around the cover to cover over an opening tray section, to form a substantially closed box.

BRIEF DESCRIPTION OF THE DRAWINGS

Other objects and features of the present invention will become apparent from the following detailed description considered in connection with the accompanying drawings. It should be understood, however, that the drawings are designed for the purpose of illustration only and not as a definition of the limits of the invention.

In the drawings, wherein similar reference characters denote similar elements throughout the several views:

FIG. 1 is an unfolded (planar) cover blank for a tray;

FIG. 2 is a plan view of an unfolded insert blank for the tray

FIG. 3 is a plan view of a floor for the tray;

FIG. 4 is a plan view of all of the parts of the device;

FIG. 5A is a plan view of the second cover;

FIG. 5B is a plan view of the insert;

FIG. 6 is a plan view of the first cover;

FIG. 7 is a top view of the insert in a folded position;

FIG. 8 is a top view of the box with the cover on the insert in a folded position; and

FIG. 9 is a top view of the box with the additional cover on it.

DETAILED DESCRIPTION

Referring firstly to FIG. 1 there is shown an unfolded (planar) cover blank for a tray according to the present invention, generally designated 10. The cover 10 comprises a rectangular panel 12 with a flap 14 appended to each side of the panel 12. A portion 16 of each flap 14 is connected to an adjacent flap 14 with a gusset 18. Each flap 14 has a tab 20 appended thereto. Two opposing flaps 14 are further provided with secondary tabs 22. The cover 10 is of light card or card board which is typically in the thickness range 0.1-0.25 mm. FIG. 2 is a plan view of an unfolded insert blank for the tray manufactured with the blank of FIG. 1, generally designated 30. The insert 30 comprises a rectangular base 32 which is substantially the same size as the panel 12. The base 32 has a wall 34 appended to each side. The insert 30 is of heavy cardboard and is typically in the range 0.5-3 mm. The walls 34 are intended to be folded-up at right angles, and are of the same height. FIG. 3 is a plan view of a floor 36 for the tray manufactured from the blank of FIG. 1. The floor 36 is of the same light card as the cover 10. The floor 36 comprising a rectangle which is substantially the same size as the panel 12. Assembly of a tray according to the present invention will now be described. The insert 30 is placed on the blank 10 so that the base 32 is aligned with the panel 12. The four walls 34 of the insert 30 are each folded-up by 90° so that the insert form a tray-like shape. The gussets 18 are then folded inwards to the tray which raises the flaps 14 by 90° thereby positioning the portions 16 against the walls 34. The remaining portion of each of the flaps 14 is then folded over each wall 34 of the insert 12. Each of the four tabs 20 are then folded so that they make contact with the base 32. The floor 36 is then located in the tray so that it is aligned with the base 32 and panel 30. The floor 36 is then bonded to the tabs 20 to form an assembled tray. It will be appreciated that numerous variations in assembly of the cover 10, insert 30 and floor 36 are possible together with the step of application of adhesive, without departing from the scope of the invention. It will also be appreciated that two trays according to the invention could be manufactured whereby one is smaller than the other, the larger tray capable of being placed over the smaller tray to provide a closure therefor.

In another embodiment, FIG. 4 shows an array of three different box type components, which can be folded and coupled together to form a new box. For example, there is a first optional outer cover 100, a second stiffening support element 200, and a third decorative cover 300. The stiffening support element 200 remains on the inside, covering 300 covers the stiffening support element 200, while the outer covering 100 optionally wraps around the covering 300.

FIG. 5A shows a plan view of cover 100. Cover or cover blank 100 is a planar type sheet, which includes a first flap 110 and a crease or divider 115 dividing between first flap 110 and a first side panel 120. First side panel 120 is separated from a base panel 130 via a crease 125. There is also a second or additional side panel 140 coupled to base or bottom 130 via crease or divider 135. There is also a second or additional flap 150 coupled to second or additional side panel 140 via crease or divider 145. These creases or dividers 115, 125, 135, and 145 can be formed as a living hinge, which is essentially a preset crease, which divides the different flaps or side panels from each other.

FIG. 5B discloses a plan view of the stiffening support element 200. Stiffening support element 200 includes a first side outer tab 210 separated from first side outer flap 216 via crease or divider 214. There's also an additional crease or divider 218 on the opposite side of first side outer flap 216. A first spacer flap 220 is coupled to first side outer flap 216 via crease or divider 218. First spacer flap 220, is coupled to first side inner flap 224 via crease or divider 222.

First side inner flap 224 is coupled to base 230 via crease or divider 226. Base 230 serves as the floor for the boxlike structure. Coupled to each end of base 230 are end flaps 240 and 250. First end flap 240 is separated from base 230 via crease or divider 232. Second end flap 250 is separated from base 230 via crease or divider 236. There is also a first end spacer flap 244 and a second end spacer flap 254, separated respectively from first end flap 240 and second end flap 250 via crease or dividers 242 and 252 respectively. There is also a first end outer flap 280 and a second and outer flap 290 separated from first end inner flap 240 and second and inner flap 250 respectively. This separation is at creases or dividers 246 and 256, respectively. There is also a first and outer tab 284 and a second and outer tab 294, wherein these outer tabs are respectively separated from first end outer flap 280 and second end outer flap 290 via creases or dividers 282 and 292, respectively.

There is also a second side inner flap 260 which is separated from base 230 via divider or crease 234. There is also a second spacer flap 264 coupled to second side inner flap 260 via crease or divider 262. Both the first spacer flap 220 and second spacer flap 264 have sides 220 a, 220 b, 264 a, 264 b that are angled in to create a notch. In addition, spacer flaps 244 and 254 also have sides 244 a, 244 b, and 254 a and 254 b that are angled in, such that once these flaps are folded over, they create a beveled edge.

There is also a second side outer flap 270 which is coupled to second spacer flap 264 via a crease or divider 266. In addition, there is a second side outer tab 274, which is coupled to second side outer flap 270 via a crease or divider 272.

FIG. 6 shows a plan view of the outer cover 300. With this design, there is a first side outer tab 310, which is coupled to a first side outer flap 314 via a first crease or divider 312. In addition, coupled to first side outer flap 314, is a first end flap of the first side 318 and a second end flap of the first side 319. These end flaps, are respectively separated via creases or dividers 316 and 317.

First spacer flap 320 is coupled to first side outer flap 314 via crease or divider 321. In addition, there is also another crease or divider 323, which separates spacer flap 320 from first side inner flap 324. On each end of first side inner flap 324 are gussets 330 and 332. Gusset 330 is separated from first side inner flap 324 via crease or divider 325. In addition, gusset 332 is separated from first side inner flap 324 via crease or divider 327. There are also creases 331 and 335 respectively which diagonally bisect gussets 330 and 332. Furthermore, gussets 330 and 332 are separated from first and inner flap 344 and second end inner flap 342 via creases or dividers 333 and 337 respectively.

In addition, first side inner flap 324 is separated from base 340 via crease divider 339. First end inner flap 344 and second end inner flap 342 are coupled to opposite ends of base 340 via creases or dividers 341 and 343 respectively. There are also a first end spacer flap 352 and a second end spacer flap 362 coupled to first end inner flap 344 and second and inner flap 342 respectively. These spacer flaps are coupled to the end flaps at creases or dividers 347 and 349, respectively. There is also a first end outer flap coupled to the first end inner flap 344 via crease or divider 351. In addition, a second end outer flap 360 is coupled to spacer divider or second end spacer flap 362 via crease or divider 361.

In addition, there are outer tabs including a first end outer tab 354 and a second end outer tab 364 wherein first end outer tab 354 is coupled to first end outer flap 350 via crease or divider 353. In addition, second end outer tab 364 is coupled to second end outer flap 360 via crease or divider 363.

There are also gussets 372 and 374, wherein these gussets are coupled to first end inner flap 344 and second end inner flap 342 respectively. These gussets 372 and 374 each have a dividing crease 373 and 375 respectively bisecting the gussets in a diagonal manner. In addition, these gussets are coupled to second side inner flap 370 via creases 371 and 377, respectively. There is also a second spacer flap 376, which is coupled to second side inner flap 370 via crease or divider 379. Second spacer flap 376 is coupled to second side outer flap 380 via crease or divider 381. In addition, there is a first end flap of the second side 382, and a second end flap of the second side 384, which are coupled to second side outer flap 380 via creases or dividers 383 and 385, respectively. There is also a second side outer tab 388, which is coupled to second side outer flap 380 via a crease or divider 387.

This outer cover 300 can include tabs or a series of flaps which can have angled edges. For example, first side outer tab 310 and second side outer tab 388 each have angled edges 310 a and 310 b and also 388 a and 388 b respectively. Furthermore, the first end flap 318 of the first side, and second end flap 319 of the first side each include an angled edge 318 a and 319 b respectively, while first end flap of the second side 382 and second end flap 384 of the second side 384, each include angled edges 382 a and 384 a respectively. Furthermore, first end spacer flap 352 includes angled edges 352 a and 352 b, as well. Second end spacer flap 362 includes angled edges 362 a and 362 b. Furthermore, first end outer tab 354 and second and outer tab 364 each include angled edges 354 a and 354 b as well as 364 a and 364 b respectively.

These angled edges are created such that when the different tabs or flaps are folded together, these angled edges create beveled edges such that these different parts will fold together to form a uniform joined box having beveled edges.

For example, when insert 200 is folded up, first side outer tab 210 serves as a floor, while first side outer flap 216 serves as an inner wall. In addition, first spacer flap 220 serves as an upper top wall with beveled edges 220 a and 220 b. First side inner flap 224 serves as an outer wall of the box. Similarly, second side outer tab 274 serves as a floor while second side outer flap 270 serves as an inner wall. Second side spacer flap 264 serves as a top surface opposite floor 274, wherein this top edge 264 has beveled top surface 264 which has beveled edges 264 a and 264 b. In this position, second side inner flap 260 serves as an outer wall of the box. In addition, when the ends are folded up, first end outer tab 284 is folded down into a bottom floor for the wall. While first end outer flap 280 serves as an inner portion of the wall. First end spacer flap 244 serves as a top edge or top surface to the wall wherein first end spacer flap 244 has beveled edges 244 a and 244 b. First inner end flap 240 serves as the outer wall for this box.

In addition, as the other end is folded up into a wall, second end outer tab 294 is folded down and serves as a floor as well. In addition, second end outer flap 290 serves as the inner wall. Second end spacer flap 254 serves as the upper portion of the wall opposite the opposite floor 294 wherein second end spacer flap 254 has beveled edges 254 a and 254 b, which would meet with beveled edges 220 a and 264 b respectively. Second an inner flap 250 then serves as an outer wall to the end of this box.

FIG. 7 shows this device in a fold up matter such that all the tabs and flaps are folded into a box. Thus, once this insert is folded up, beveled edge 220 a matches with beveled edge 244 a, while beveled edge 244 b matches or mates with beveled edge 264 a. In addition, beveled edge 264 b matches with beveled edge 254 b while beveled edge 254 a matches or mates with beveled edge 220 a.

FIG. 8 which shows the initial cover 300, can be folded up over insert 200. This design can also be presented as a final version of a tray without a cover. For example, first side outer tab 310 (See FIG. 6) folds up over crease line or divider 312 to form a floor. In this case, first side outer flap 314 forms an outer wall. While first spacer flap 320 forms an upper wall surface. First side inner flap 324, forms an outer wall while gussets 330 and 332 fold in and can be tucked in, either in front of or between the inner and outer walls formed on insert 200. These gussets 330 and 332 fold along fold lines 331 and 335, respectively.

Similarly, second side outer tab 388 is folded down to form a flat base, while second side outer flap 380 forms an inner wall covering for covering second side outer flap 270 on insert 200. In addition, second side inner flap 370 forms an outer wall covering for covering second side inner flap 260. In addition, gussets 372 and 374 are folded up and in and can be tucked in between the inner and outer walls of insert 200. Alternatively, these gussets can be tucked in behind second side outer flap 380 forming a cover over the inner wall formed by second side outer flap 270.

In addition, first end outer tab 354 and second end outer tab 364 can be folded down to provide a base floor contact. In addition, first end outer flap 350 and second end outer flap 360 a fold up over it. And in front of the inner walls formed by first end outer flap 280 and second end outer flap 290 on insert 200. In addition, first end spacer flap 352 and second end spacer flap 362 are folded up and over first end spacer flap 244 and second end spacer flap. 264 to form a top cover over these respective spacer flap.

In this case, first inner end flap 344 and second end inner flap 342 form outer wall coverings for first end inner flap 240 and second end inner flap 250 respectively. In this folded up position, beveled edge 318 a matches or mates with beveled edge 352 a while beveled edge 310 a matches or mates with beveled edge 354 a. In addition, beveled edge 310 b matches or mates with beveled edge 364 a while beveled edge 319 a matches or mates with beveled edge 362 a. In addition, beveled edge 362 b matches or mates with beveled edge 384 a while beveled edge 364 b matches or mates with beveled edge 388 b. Furthermore, beveled edge 388 a matches or mates with beveled edge 354 b while beveled edge 352 b matches or mates with beveled edge 382 a. This covering would then form a sufficient decorative covering while insert 200 provides structural strength to the box.

When second cover 100 is then coupled to the box or tray, first side panel 120 matches with base 230 and base 340 to form a bottom cover section. In addition, second or additional side panel 140 forms a top cover portion, covering an opening or gap in the tray or box to create a closed box. In this case, second or additional side panel 140 covers on top of spacer flaps 220 and 264 and also spacer flaps 320 and 362 to form a top cover. In this case, this final version is shown in FIG. 9, as a closed box. With this design, first flap 110 can form a sealing flap which can be adhered to second or additional flap 150 to form a closed cover. Thus, this design forms an intricate and decorative box, which can be easily assembled and manufactured.

Accordingly, while a few embodiments of the present invention have been shown and described, it is to be understood that many changes and modifications may be made thereunto without departing from the spirit and scope of the invention as defined in the appended claims. 

1. A packaging box comprising: a) a tray comprising i) a cover comprising: a) a planar rectangular panel having a flap on each edge; b) a gusset coupling at least one flap to an adjacent flap; and c) at least one tab coupled to at least one flap; ii) an insert comprising a) a planar rectangular base which is substantially the same size as said planar rectangular panel; b) a plurality of flaps coupled to said base with at least one flap coupled to each edge of said base; c) at least one additional cover, comprising a planar rectangle, wherein in use, said first cover is wrapped around said insert to form a full cover over said insert while said at least one additional cover is wrapped around said cover to cover over an opening tray section, to form a substantially closed box.
 2. A box according to claim 1, wherein the insert is of a card like material.
 3. A box according to claim 2, wherein the card has a thickness in the range 0.5-3 mm.
 4. A box according to claim 2, wherein the card has a thickness is in the range 0.8-2 mm.
 5. A box according to claim 2, wherein the card is comprised of recycled chipboard.
 6. A box according to claim 1, wherein the cover is bonded to the insert at spaced locations.
 7. The box as in claim 1, wherein said cover further comprises at least one spacer panel having at least one beveled edge.
 8. The box as in claim 7, wherein each tab on said cover has a beveled edge.
 9. The box as in claim 1, wherein said insert further comprises at least one spacer flap having a beveled edge.
 10. The box as in claim 9, wherein said at least one spacer flap comprises at least four spacer flaps and wherein when said insert is folded into a tray, said at least one spacer flap forms a top surface of said tray.
 11. A method of assembling a box comprising the steps of: providing a pre-formed planar cover comprising a rectangular panel forming a floor with at least one flap on each edge forming a wall, a portion of each flap being connected to an adjacent flap with a gusset, and at least one flap having a tab at the free edge thereof, providing an insert blank comprising a rectangular base forming a floor, the base having flaps on each edge forming a wall portion, and placing the insert blank on the cover; folding said walls of said insert blank upright so that the insert forms a tray-like shape, folding said flaps of said cover over the walls of said insert, folding each gusset inward of said cover to form a tray-like shape cover over said insert; folding at least one of said tabs on said cover onto said floor, and coupling said tabs to said floor of said blank to secure said cover to said insert; coupling said additional cover to said tray to cover said tray.
 12. A method according to claim 12, further comprising the step of providing opposite flaps with secondary tabs and adhesively bonding said secondary tabs to said adjacent flaps.
 13. The method as in claim 11, wherein said additional cover covers an opening in said tray.
 14. The method as in claim 13, wherein said additional cover is coupled to said cover by folding over said cover and then coupling at least two end portions of said additional cover together via an adhesive.
 15. The method as in claim 11, wherein said tabs are coupled to said floor of said insert via an adhesive.
 16. A tray comprising: a) a cover comprising: i) a planar rectangular panel having a flap on each edge; ii) a gusset coupling at least one flap to an adjacent flap; and iii) at least one tab coupled to at least one flap; b) an insert comprising i) a planar rectangular base which is substantially the same size as said planar rectangular panel; and ii) a plurality of flaps coupled to said base with at least one flap coupled to each edge of said base wherein said cover is folded over said insert to form a cover for said insert.
 17. A method of assembling a tray comprising the steps of: providing a pre-formed planar cover comprising a rectangular panel forming a floor with at least one flap on each edge forming a wall, a portion of each flap being connected to an adjacent flap with a gusset, and at least one flap having a tab at the free edge thereof, providing an insert blank comprising a rectangular base forming a floor, the base having flaps on each edge forming a wall portion, and placing the insert blank on said cover; folding said walls of said insert blank upright so that said insert forms a tray-like shape, folding said flaps of said cover over said walls of said insert, folding each gusset inward of said cover to form a tray-like shape cover over said insert; folding at least one of said tabs on said cover onto said floor, and coupling said tabs to said floor of said blank to secure said cover to said insert to form a tray. 